Modular approach for advanced battery modules having different electrical characteristics

ABSTRACT

Present embodiments include a series of lithium battery modules having a plurality of electrochemical cells having different electrical characteristics such as voltages and/or capacities. The battery modules are each constructed using components, architectures, production methods, among other things, in common with each other. The lithium ion battery modules may include a first battery module type having a first capacity and a first voltage, a second battery module type having a second capacity and a second voltage, and, in some embodiments, additional battery module types (e.g., a third battery module type having a third capacity and a third voltage) having different voltages and/or capacities. The lithium ion battery modules may all have the same footprint.

BACKGROUND

The present disclosure relates generally to the field of batteries andbattery modules. More specifically, the present disclosure relates towater management features for Lithium-ion (Li-ion) battery modules.

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present disclosure,which are described and/or claimed below. This discussion is believed tobe helpful in providing the reader with background information tofacilitate a better understanding of the various aspects of the presentdisclosure. Accordingly, it should be understood that these statementsare to be read in this light, and not as admissions of prior art.

A vehicle that uses one or more battery systems for providing all or aportion of the motive power for the vehicle can be referred to as anxEV, where the term “xEV” is defined herein to include all of thefollowing vehicles, or any variations or combinations thereof, that useelectric power for all or a portion of their vehicular motive force. Forexample, xEVs include electric vehicles (EVs) that utilize electricpower for all motive force. As will be appreciated by those skilled inthe art, hybrid electric vehicles (HEVs), also considered xEVs, combinean internal combustion engine propulsion system and a battery-poweredelectric propulsion system, such as 48 Volt (V) or 130V systems. Theterm HEV may include any variation of a hybrid electric vehicle. Forexample, full hybrid systems (FHEVs) may provide motive and otherelectrical power to the vehicle using one or more electric motors, usingonly an internal combustion engine, or using both. In contrast, mildhybrid systems (MHEVs) disable the internal combustion engine when thevehicle is idling and utilize a battery system to continue powering theair conditioning unit, radio, or other electronics, as well as torestart the engine when propulsion is desired. The mild hybrid systemmay also apply some level of power assist, during acceleration forexample, to supplement the internal combustion engine. Mild hybrids aretypically 96V to 130V and recover braking energy through a belt or crankintegrated starter generator. Further, a micro-hybrid electric vehicle(mHEV) also uses a “Stop-Start” system similar to the mild hybrids, butthe micro-hybrid systems of a mHEV may or may not supply power assist tothe internal combustion engine and operates at a voltage below 60V. Forthe purposes of the present discussion, it should be noted that mHEVstypically do not technically use electric power provided directly to thecrankshaft or transmission for any portion of the motive force of thevehicle, but an mHEV may still be considered as an xEV since it does useelectric power to supplement a vehicle's power needs when the vehicle isidling with internal combustion engine disabled and recovers brakingenergy through an integrated starter generator. In addition, a plug-inelectric vehicle (PEV) is any vehicle that can be charged from anexternal source of electricity, such as wall sockets, and the energystored in the rechargeable battery packs drives or contributes to drivethe wheels. PEVs are a subcategory of EVs that include all-electric orbattery electric vehicles (BEVs), plug-in hybrid electric vehicles(PHEVs), and electric vehicle conversions of hybrid electric vehiclesand conventional internal combustion engine vehicles.

xEVs as described above may provide a number of advantages as comparedto more traditional gas-powered vehicles using only internal combustionengines and traditional electrical systems, which are typically 12Vsystems powered by a lead acid battery. For example, xEVs may producefewer undesirable emission products and may exhibit greater fuelefficiency as compared to traditional internal combustion vehicles and,in some cases, such xEVs may eliminate the use of gasoline entirely, asis the case of certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improvedpower sources, particularly battery modules, for such vehicles and otherimplementations. For example, traditional battery modules may beconstructed on an individually-designed basis, meaning that eachtraditional battery module may be designed for a specific implementation(e.g., voltage and capacity). Accordingly, each type of traditionalbattery module may use components specifically selected for that module.It is now recognized that in traditional approaches, it may be difficultto construct battery modules for different applications, but using ashared approach and source of components for the modules. Indeed, it isnow recognized that it may be desirable to provide battery modules thatutilize a set of common (shared) components, and other shared features.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. Itshould be understood that these aspects are presented merely to providethe reader with a brief summary of these certain embodiments and thatthese aspects are not intended to limit the scope of this disclosure.Indeed, this disclosure may encompass a variety of aspects that may notbe set forth below.

Present embodiments are directed toward a series of battery moduleshaving a plurality of electrochemical cells (which may also be referredto as battery cells herein) having different voltages and/or capacities,where the battery modules are each constructed using components,architectures, production methods, among other things, in common witheach other. For example, in certain implementations of the presentapproach, the battery modules may include a first battery module typehaving a first capacity and a first voltage, a second battery moduletype having a second capacity and a second voltage, and, in someembodiments, additional battery module types (e.g., a third batterymodule type having a third capacity and a third voltage) havingdifferent voltages and/or capacities.

For example, in one aspect, the present disclosure relates to a lithiumion battery module product portfolio, including a first lithium ionbattery module product having a first housing configured to receive afirst set of prismatic electrochemical cells, the housing including abase having a first footprint; a second lithium ion battery moduleproduct having a second housing configured to receive a second set ofprismatic electrochemical cells, the second housing including a basehaving a second footprint that is substantially the same as the firstfootprint. A vertical profile opposing the base of the first and secondhousings is different for each of the first and second lithium ionbattery module products, and each prismatic electrochemical cell of thefirst and second sets of prismatic electrochemical cells conforming tothe same manufacturing specifications. The first housing of the firstlithium ion battery module product is sized to fit a first number of theprismatic electrochemical cells, the second housing of the secondlithium ion battery module product is sized to fit a second number ofthe prismatic electrochemical cells, and the first and second numbers ofthe prismatic lithium ion electrochemical cells are different. Thelithium ion battery module product portfolio also includes a componentconfigured to interchangeably couple with a first region of the firsthousing of the first lithium ion battery module product and a secondregion of the second housing of the second lithium ion battery moduleproduct, the first and second regions having corresponding locations onthe first and second housings.

In another aspect, the present disclosure also relates to a method ofmanufacturing lithium ion battery modules. The method includes producinga first lithium ion battery module by a first process that includesdisposing a first number of prismatic electrochemical cells having a setof standardized dimensions in a first housing, the first housing havinga first base with a length and a width, and electrically connecting thefirst number of prismatic electrochemical cells such that the firstlithium ion battery module has a first voltage and a first capacity. Themethod also includes producing a second battery module by a secondprocess, the second process including disposing a second number ofprismatic electrochemical cells having the set of standardizeddimensions in a second housing different from the first housing, thesecond housing having a second base with the length and the width, andelectrically connecting the second number of prismatic electrochemicalcells such that the second lithium ion battery module has a secondvoltage and a second capacity. The first process and the second processcollectively comprise using a type of component configured tointerchangeably couple with a first region of the first housing of thefirst lithium ion battery module and a second region of the housing ofthe second lithium ion battery module, the first and second regionshaving the same location on their first and second housings,respectively.

In yet another aspect, the present disclosure also relates to a lithiumion battery module product portfolio, including a first lithium ionbattery module product having a first layout. The first layout includesa first module housing configured to house a first set ofelectrochemical cells. The first module housing includes a first topportion having terminals configured to provide a voltage output of thefirst lithium ion battery module product, a first base disposed oppositethe top portion and having a set of dimensions; and a first cellreceptacle region disposed between the first top portion and the firstbase, the first cell receptacle region being configured to receive thefirst set of electrochemical cells in an orientation. The system alsoincludes a second lithium ion battery module product having a secondlayout, the layout including a second module housing configured to housea second set of electrochemical cells, the second set of electrochemicalcells having a greater number of electrochemical cells compared to thefirst set of electrochemical cells. The second module housing includes asecond top portion having terminals configured to provide a voltageoutput of the second lithium ion battery module, a second base disposedopposite the second top portion and having the same set of dimensions asthe first base, and a second cell receptacle region disposed between thesecond top portion and the second base, the second cell receptacleregion being configured to receive the second set of electrochemicalcells in the orientation. The system further includes a plurality ofcomponents configured to interchangeably couple with a plurality ofcorresponding first regions of the first battery module housing and aplurality of corresponding second regions of the second module housing,and the first and second layouts are such that the corresponding firstand second regions have the same location on their respective housings.

DRAWINGS

FIG. 1 is a perspective view of an xEV having a battery systemconfigured in accordance with present embodiments to provide power forvarious components of the xEV, in accordance with an aspect of thepresent disclosure;

FIG. 2 is a cutaway schematic view of an embodiment of the xEV having astart-stop system that utilizes the battery system of FIG. 1, thebattery system having a lithium ion battery module, in accordance withan aspect of the present disclosure;

FIG. 3 is a schematic representation of a layout of an embodiment of thelithium ion battery module of FIG. 2, in accordance with an aspect ofthe present disclosure;

FIG. 4 is a perspective view of an embodiment of the lithium ion batterymodule of FIG. 2 having various components that may be used in otherversions of a lithium ion battery module, in accordance with an aspectof the present disclosure;

FIG. 5 is a perspective view of an embodiment of the lithium ion batterymodule of FIG. 2 having various components that may be used in otherversions of a lithium ion battery module, in accordance with an aspectof the present disclosure;

FIG. 6 is a perspective view of an embodiment of the lithium ion batterymodule of FIG. 2 having various components that may be used in otherversions of a lithium ion battery module, in accordance with an aspectof the present disclosure;

FIG. 7 is a block diagram representing an embodiment of a manufacturingsystem configured to produce a set of lithium ion battery modules havinga plurality of common components, in accordance with an aspect of thepresent disclosure;

FIG. 8 is a block diagram representing an embodiment of a region of themanufacturing system of FIG. 7 in which various shared components may beincorporated into a variety of different lithium ion battery modules, inaccordance with an aspect of the present disclosure;

FIG. 9 (FIGS. 9A and 9B) is a combined exploded perspective view of theembodiments of the lithium ion battery modules of FIGS. 4 and 5 andhighlighting various shared components between the modules, inaccordance with an aspect of the present disclosure;

FIG. 10 (FIGS. 10A and 10B) is a combined exploded perspective view ofthe embodiments of the lithium ion battery modules of FIGS. 4 and 6 andhighlighting various shared components between the modules, inaccordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effortto provide a concise description of these embodiments, not all featuresof an actual implementation are described in the specification. Itshould be appreciated that in the development of any such actualimplementation, as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the presentdisclosure, the articles “a,” “an,” and “the” are intended to mean thatthere are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features.

The battery systems described herein may be used to provide power tovarious types of electric vehicles (xEVs) and other high voltage energystorage/expending applications (e.g., electrical grid power storagesystems). Such battery systems may include one or more battery modules,each battery module having a housing and a number of battery cells(e.g., Lithium-ion (Li-ion) electrochemical cells) arranged within thehousing to provide particular voltages and/or currents useful to power,for example, one or more components of an xEV. As another example,battery modules in accordance with present embodiments may beincorporated with or provide power to stationary power systems (e.g.,non-automotive systems).

Present embodiments are directed toward a lithium ion battery moduleproduct portfolio including a series of battery module products having aplurality of electrochemical cells (which may also be referred to asbattery cells) having different electrical characteristics such asvoltages and/or capacities, where the battery module products are eachconstructed using components, architectures, production methods, amongother things, in common with each other. For example, in certainimplementations of the present approach, the battery module products(also referred to herein individually as a “battery module” andcollectively as “battery modules”) may include a first battery moduletype (e.g., a first battery module product) having a first capacity anda first voltage, a second battery module type (e.g., a second batterymodule product) having a second capacity and a second voltage, and, insome embodiments, additional battery module types (e.g., a third batterymodule type or product having a third capacity and a third voltage)having different voltages and/or capacities.

Again, the battery module types (e.g., a battery module products) maydiffer in voltage and/or capacity, but may have a number of similarcomponents that may be utilized in any of the different designs in amodular fashion. For instance, these modular components may include, butare not limited to, battery cells, terminals, bus bar connections, shuntbridges, side plugs, fans, low voltage connectors, relays, printedcircuit boards (PCBs), and fan filters.

Not only are the same types of components used across the differentbattery module types or products, but the battery module types alsoinclude housings that, while different in terms of the number of batterycells they may hold, ultimately include features that perform the samefunctions in substantially the same way. That is, the different batterymodule types include similar design concepts for their respectivehousings, including similar receptacles for the similar components and,in some embodiments, a similar layout.

Though there may be two, three, or more different battery module typesdepending, for example, on the number of battery cells utilized in thebattery module and the manner in which they are connected, the presentembodiments are described in the context of two or three battery modules(which are also battery module products as described herein). Forexample, two battery modules may have a similar voltage rating butdifferent capacities, and a third battery module may have a differentvoltage but the same capacity as one of the other two battery modules.However, any combination of overlapping voltages and/or capacities isencompassed by the present disclosure.

As set forth above, in certain xEV contexts (among others, such asnon-automotive or stationary energy expending applications), a 12 Voutput from a lithium ion battery module may be desirable to powercertain types of components (e.g., similar types of componentstraditionally powered by a traditional lead acid battery in traditionalvehicles), while a 48 V output may be more suitable to power other typesof components that may require a higher voltage, such as an airconditioning system. With this in mind, it is now recognized that thepresent battery module embodiments may be particularly applicable tosuch types of battery modules.

By way of non-limiting example, the different battery modulesconstructed in accordance with the modular approaches described hereinmay include a first battery module type having a voltage of 12V and acapacity of 10 Amp hours (Ah), a second battery module type having avoltage of 12V and a capacity of 20 Ah, and a third battery module typehaving a voltage of 48V and a capacity of 10 Ah.

To help illustrate, FIG. 1 is a perspective view of an embodiment of avehicle 10, which may utilize a regenerative braking system. Althoughthe following discussion is presented in relation to vehicles withregenerative braking systems, the techniques described herein areadaptable to other vehicles that capture/store electrical energy with abattery, which may include electric-powered and gas-powered vehicles.

It is now recognized that it is desirable for a non-traditional batterysystem 12 (e.g., a lithium ion car battery) to be largely compatiblewith traditional vehicle designs. In this respect, present embodimentsinclude various types of battery modules for xEVs and systems thatinclude xEVs. Accordingly, the battery system 12 may be placed in alocation in the vehicle 10 that would have housed a traditional batterysystem. For example, as illustrated, the vehicle 10 may include thebattery system 12 positioned similarly to a lead-acid battery of atypical combustion-engine vehicle (e.g., under the hood of the vehicle10). Furthermore, as will be described in more detail below, the batterysystem 12 may be positioned to facilitate managing temperature of thebattery system 12. For example, in some embodiments, positioning abattery system 12 under the hood of the vehicle 10 may enable an airduct to channel airflow over the battery system 12 and cool the batterysystem 12.

A more detailed view of the battery system 12 is described in FIG. 2. Asdepicted, the battery system 12 includes an energy storage component 14coupled to an ignition system 16, an alternator 18, a vehicle console20, and optionally to an electric motor 22. Generally, the energystorage component 14 may capture/store electrical energy generated inthe vehicle 10 and output electrical energy to power electrical devicesin the vehicle 10.

In other words, the battery system 12 may supply power to components ofthe vehicle's electrical system, which may include radiator coolingfans, climate control systems, electric power steering systems, activesuspension systems, auto park systems, electric oil pumps, electricsuper/turbochargers, electric water pumps, heated windscreen/defrosters,window lift motors, vanity lights, tire pressure monitoring systems,sunroof motor controls, power seats, alarm systems, infotainmentsystems, navigation features, lane departure warning systems, electricparking brakes, external lights, or any combination thereof.Illustratively, in the depicted embodiment, the energy storage component14 supplies power to the vehicle console 20 and the ignition system 16,which may be used to start (e.g., crank) the internal combustion engine24.

Additionally, the energy storage component 14 may capture electricalenergy generated by the alternator 18 and/or the electric motor 22. Insome embodiments, the alternator 18 may generate electrical energy whilethe internal combustion engine 24 is running. More specifically, thealternator 18 may convert the mechanical energy produced by the rotationof the internal combustion engine 24 into electrical energy.Additionally or alternatively, when the vehicle 10 includes an electricmotor 22, the electric motor 22 may generate electrical energy byconverting mechanical energy produced by the movement of the vehicle 10(e.g., rotation of the wheels) into electrical energy. Thus, in someembodiments, the energy storage component 14 may capture electricalenergy generated by the alternator 18 and/or the electric motor 22during regenerative braking. As such, the alternator and/or the electricmotor 22 are generally referred to herein as a regenerative brakingsystem.

To facilitate capturing and supplying electric energy, the energystorage component 14 may be electrically coupled to the vehicle'selectric system via a bus 26. For example, the bus 26 may enable theenergy storage component 14 to receive electrical energy generated bythe alternator 18 and/or the electric motor 22. Additionally, the busmay enable the energy storage component 14 to output electrical energyto the ignition system 16 and/or the vehicle console 20. Accordingly,when a 12 volt battery system 12 is used, the bus 26 may carryelectrical power typically between 8-18 volts.

Additionally, as depicted, the energy storage component 14 may includemultiple battery modules. For example, in the depicted embodiment, theenergy storage component 14 includes a lithium ion (e.g., a first)battery module 28 and a lead-acid (e.g., a second) battery module 30,which each includes one or more battery cells. In other embodiments, theenergy storage component 14 may include any number of battery modules.Additionally, although the lithium ion battery module 28 and lead-acidbattery module 30 are depicted adjacent to one another, they may bepositioned in different areas around the vehicle. For example, thelead-acid battery module may be positioned in or about the interior ofthe vehicle 10 while the lithium ion battery module 28 may be positionedunder the hood of the vehicle 10.

In some embodiments, the energy storage component 14 may includemultiple battery modules to utilize multiple different batterychemistries. For example, when the lithium ion battery module 28 isused, performance of the battery system 12 may be improved since thelithium ion battery chemistry generally has a higher coulombicefficiency and/or a higher power charge acceptance rate (e.g., highermaximum charge current or charge voltage) than the lead-acid batterychemistry. As such, the capture, storage, and/or distribution efficiencyof the battery system 12 may be improved.

To facilitate controlling the capturing and storing of electricalenergy, the battery system 12 may additionally include a control module32. More specifically, the control module 32 may control operations ofcomponents in the battery system 12, such as relays (e.g., switches)within energy storage component 14, the alternator 18, and/or theelectric motor 22. For example, the control module 32 may regulateamount of electrical energy captured/supplied by each battery module 28or 30 (e.g., to de-rate and re-rate the battery system 12), perform loadbalancing between the battery modules 28 and 30, determine a state ofcharge of each battery module 28 or 30, determine temperature of eachbattery module 28 or 30, control voltage output by the alternator 18and/or the electric motor 22, and the like.

Accordingly, the control unit 32 may include one or processor 34 and oneor more memory 36. More specifically, the one or more processor 34 mayinclude one or more application specific integrated circuits (ASICs),one or more field programmable gate arrays (FPGAs), one or more generalpurpose processors, or any combination thereof. Additionally, the one ormore memory 36 may include volatile memory, such as random access memory(RAM), and/or non-volatile memory, such as read-only memory (ROM),optical drives, hard disc drives, or solid-state drives. In someembodiments, the control unit 32 may include portions of a vehiclecontrol unit (VCU) and/or a separate battery control module.Furthermore, as depicted, the lithium ion battery module 28 and thelead-acid battery module 30 are connected in parallel across theirterminals. In other words, the lithium ion battery module 28 and thelead-acid module 30 may be coupled in parallel to the vehicle'selectrical system via the bus 26.

It should be noted that presently disclosed embodiments may beapplicable to any battery module having the same or differentconfigurations and/or orientations described above and in detail below.One of ordinary skill in the art would recognize that the components andexamples used to describe battery modules in accordance with the presentdisclosure should not be construed to limit the present disclosure tothose components and examples alone. Rather, the disclosed examples aremerely intended to serve as non-limiting examples to facilitatediscussion of the present disclosure.

As set forth above, in accordance with the present disclosure, differenttypes of the lithium ion battery module 28 (e.g., a lithium ion batterymodule product portfolio including different lithium ion battery moduleproducts) may utilize components of the same type and may have similargeometrical features (e.g., layout, overall architecture). An exampleembodiment of the layout of the lithium ion battery module 28 isillustrated in FIG. 3. Specifically, the illustrated embodiment of thelithium ion battery module 28 includes a housing 40, which is intendedto represent a one-piece housing or a multi-piece housing (e.g.,two-piece, three-piece, or more). To facilitate discussion, differentsections of the housing 40 (which may or may not correspond to sectionsof the overall lithium ion battery module 28) may be defined as follows:a base 42, which may also be referred to as a bottom portion andgenerally defines the footprint of the lithium ion battery module 28when placed in operation (e.g., in the xEV 10), sides including a leftside 44 and a right side 46, and a top region or top portion 48. The topportion 48 is generally opposite the base 42, with the sides generallyextending between the two. The left side 44 and right side 46 aredetermined, in the illustrated embodiment, with reference to a cellreceptacle region 50, which may be considered to correspond to a frontend 52 of the lithium ion battery module 28. As described in furtherdetail below, the cell receptacle region 50 is configured to receive aplurality of battery cells (e.g., prismatic electrochemical cells) in aparticular orientation. A back end 54 of the lithium ion battery module28 may be considered to correspond to an end opposite the cellreceptacle region 50 (and, accordingly, opposite the front end 52). Inaccordance with present embodiments, these different sections of thelithium ion battery module 28 may have substantially the same layoutand/or configuration across multiple versions, meaning that similarcomponents (e.g., components from the same source), referred to ascomponents of the same type, may be located in these regions. It shouldbe noted that the battery module 28 of FIG. 3 is intended to representmultiple versions (e.g., individual products of a product portfolio),also referred to as embodiments or types, of lithium ion battery moduleshaving the same regions located in the same (e.g., corresponding from alocation standpoint) portion of the battery module relative to all otherfeatures of the battery module. For example, a region of the lithium ionbattery module 28 of FIG. 3 is intended to represent first, second,third, fourth, and so on, regions of the housing 40 corresponding tofirst, second, third, fourth, and so on, respective embodiments of thebattery module 28.

In accordance with the present disclosure, the phrase “common component”or “shared component” is intended to denote a component that can beinterchangeably coupled for use in a set of different types of thelithium ion battery module 28, where the component is provided from acommon source. For instance, a source of a particular one component suchas a particular relay, a particular bus bar, a particular battery cell,and so forth, may be interchangeably used in the different types oflithium ion battery modules 28 set forth herein. That is, common orshared components are interchangeable, and have dimensions to withinmanufacturing tolerances of their common source.

In accordance with an aspect of the present disclosure, one commonlayout for the different versions of the lithium ion battery module 28may include an electrical layout 56 of the top region 48. For example,the electrical layout 56, as illustrated, may include first and secondterminal regions 58, 60, corresponding to respective locations of afirst terminal and second terminal (e.g., pairs of terminals, which areshown in FIG. 4) of the lithium ion battery module 28, the terminalsbeing configured to provide an electrical output of the respectivelithium ion battery modules 28. The illustrated electrical layout 56also includes a control board region 62 corresponding to a location of acontrol board (where examples of the control board are shown in FIGS. 9and 10), and a relay region 64 corresponding to a location of a relay.Examples of the relay are shown in FIGS. 9 and 10. It should be notedthat the regions 58, 60, 62, 64 are not only locations corresponding tothese components, but also may include certain features (e.g.,receptacle areas, connectors, pegs, electrical traces) that enable thatparticular region to interface with these components, and, in certainembodiments enable them to interface and house the components in aparticular way.

The sides of the lithium ion battery module 28 (e.g., the housing 40)may also be configured in this manner. For example, the left and/orright sides 44, 46 (located laterally with respect to the cellreceptacle region 50) may include a vent region 66, corresponding to alocation where gases may be vented out of the module 14. The vent region66 may include one or more features configured to interface with, forexample, vent plugs, vent adapters for hose connections of a vehicle,and the like. It should be noted that the disclosed embodiments are notlimited to these regions and the particular components set forth above.Rather, there may be other features, including but not limited to thosedescribed in further detail below. For example, the lithium ion batterymodules 28 configured in accordance with present embodiments may alsoinclude regions specifically configured to couple with other components,such as fans, fan filters, fan covers, thermal management features, andthe like.

As set forth above, the base 42 of the lithium ion battery module 28generally defines its footprint. With regard to vehicle integration,this can be an important design concern in that certain sizes for thebase 42 may be desired for integration into a particular vehicle due to,for example, spatial constraints. Indeed, in embodiments where the xEV10 of FIGS. 1 and 2 is a micro-hybrid, it may be desirable for the base42 to be a size that enables the lithium ion battery module 28 to belocated relatively close to a lead acid battery, close to an alternator,etc. Thus, the lithium ion battery module 28 may be a size that enablesvehicle integration, as an example, under a hood of the xEV 10, orwithin a cage located toward a front of the xEV 10.

With this in mind, one aspect of the present disclosure providesembodiments in which first, second, and third types of the lithium ionbattery module 28 may have substantially the same base configuration(e.g., substantially the same footprint). This aspect may be furtherappreciated with reference to FIGS. 4, 5, and 6, which respectivelydepict a first embodiment of the lithium ion battery module 28A, asecond embodiment of the lithium ion battery module 28B, and a thirdembodiment of the lithium ion battery module 28C. Again, the base 42 maybe represented by the dimensions of the portion of the battery modulehousing 40 that is ultimately mounted to or rests on a surface of thexEV 10 (e.g., closest to the ground/floor). In accordance with anembodiment, the respective housings 40 have bases 42 each having thesame dimensions.

The base 42 may generally correspond to a length (L) and a width (W) ofthe lithium ion battery module 28, and the length and width of therespective bases of the first, second, and third embodiments of thelithium ion battery modules 28 may be the same, which is intended toaccount for manufacturing tolerances. Further, although the lithium ionbattery modules 28 are intended to represent advanced battery moduleshaving lithium ion electrochemical cells, the base 42 may correspond toany one of the many group representations (e.g., Battery CouncilInternational (BCI) group numbers, Deutsche Industrie Normen (DINcodes), European Norm (EN) codes) established for traditional lead acidbatteries (e.g., lead acid battery module 30). Each group (e.g., groupnumber) from these established set of standards has a standard lengthand width for the base of the particular battery corresponding to theparticular group designation. The secondary lithium ion battery modulesdescribed herein may or may not have dimensions that substantially matchor comply with the standard dimension requirements of at least a base ofa known lead acid battery standard (e.g., a BCI group, DIN code, or ENcode).

As one example, the first, second, and third embodiments of the lithiumion battery modules 28 of FIGS. 4-6 may be sized to have an H5 (DINcode) base, which is 242 mm in length by 175 mm in width. The H5 base isalso commonly referred to as an LN2 base. However, the base 42 of thelithium ion battery modules 28 may have any length and width suitable tosubstantially match a particular base of a lead acid battery. Althoughstandardized for lead acid batteries, it can be difficult to conform tosuch standards using lithium ion electrochemical cell technologies,especially when considering that lithium ion battery modules, such asthose described herein, may be associated with equipment not found intraditional lead acid batteries such as intelligent control features,thermal management features, advanced venting features, and so forth.However, the present disclosure is not limited to the bases 42 of thelithium ion battery modules 28 being the same size as a lead acidstandard. Rather, the lithium ion battery modules 28 may have any sizefor their respective bases 42, which in certain embodiments may be thesame for the different lithium ion battery modules 28. As a non-limitingexample, the length L may be a value between 150 mm and 450 mm, and thewidth W may be a value between 100 mm and 200 mm, where the values matchfor all the modular lithium ion battery modules 28.

While the lithium ion battery modules 28 of FIGS. 4-6 have aspects orfeatures with the same configuration or layout (e.g., substantially thesame base 42 or the same lateral arrangement of terminals), it should benoted that their respective heights (e.g., vertical profiles opposingrespective bases of the housings) may differ, depending, for example, ontheir power components. For example, in FIG. 4, the lithium ion batterymodule 28 may have a first output voltage (e.g., 12 V) and a firstcapacity (e.g., 10 amp hours (Ah)). In FIG. 5, the lithium ion batterymodule 28 may have a second output voltage that is the same as the firstoutput voltage while having a second capacity greater than the firstcapacity (e.g., 20 Ah). From a power component standpoint, the lithiumion battery module 28 of FIG. 5 differs from the first lithium ionbattery module 28 of FIG. 4 by the number of total electrochemical cellsin their respective housings 40. In one embodiment, the first embodimentof the lithium ion battery module 28A of FIG. 4 may include a firstnumber (e.g., 6) of electrochemical cells electrically coupled in aserial arrangement, while the second embodiment of the lithium ionbattery module 28B of FIG. 5, which has a larger capacity (e.g., twicethe capacity), has a second number (e.g., 12) of the same type ofelectrochemical cells coupled using a combination of serial and parallelelectrical connections. The arrangement of the electrochemical cellswithin the housings 40, which is described in further detail below, isthe primary factor that causes a respective vertical profile, or heightH1 of the lithium ion battery module 28 of FIG. 4 and a verticalprofile, or respective height H2 of the lithium ion battery module 28 ofFIG. 5 to differ. For the lithium ion battery module 28 in FIG. 4, itscell receptacle region 50 and, therefore, its housing 40, is configuredto (e.g., sized to) receive (e.g., fit) a first number of prismaticelectrochemical cells conforming to a set of manufacturingspecifications, while the lithium ion battery module 28 of FIG. 5 has anembodiment of the housing 40 configured to (e.g., sized to) receive(e.g., fit) a second number of the prismatic electrochemical cells, thesecond number being greater than the first.

The third embodiment of the lithium ion battery module 28C of FIG. 6 hasa significantly larger vertical profile or height H3, compared to thelithium ion battery modules 28 of FIGS. 4 and 5. This is due, at leastin part, to the additional number of electrochemical cells required forthe lithium ion battery module 28 to reach a higher voltage (e.g., 48 Vusing a third number, such as 20, of the same type of electrochemicalcells connected in series). That is, the housing 40 of the thirdembodiment of the lithium ion battery module 28C may be configured to(e.g., sized to) receive (e.g., fit) the third number of prismaticelectrochemical cells). It should be noted that the different lithiumion battery modules 28 of FIGS. 4-6 all utilize lithium ionelectrochemical cells having standardized dimensions, which aredimensions that are intended to be produced for a particularelectrochemical cell type, and is intended to allow for manufacturingtolerances. For instance, the electrochemical cells in some embodimentsmay be prismatic electrochemical cells that have standardized dimensionsassociated with a particular tolerance.

As will be appreciated from the present disclosure, the lithium ionbattery modules 28 described herein may be modular not only from thestandpoint of their electrochemical cells and their footprint (e.g.,base 42), but also from the standpoint of their architecture and commoncomponents. For instance, the base 42 of each lithium ion battery module28 is located at an end that is substantially opposite a location of aset of terminals of the lithium ion battery module 28, illustrated as afirst terminal 70 (e.g., a positive terminal) and a second terminal 72(e.g., a negative terminal), which are positioned in the first andsecond terminal regions 58, 60, respectively. The terminals 70, 72 mayinclude a single component or a set of components that are common to(e.g., of the same type and configured to be interchangeably coupled to)the different lithium ion battery modules 28. Further, in accordancewith certain embodiments, the first and second terminal regions 58, 60are specifically configured to position terminal posts 74, 76 (e.g., anend of the terminal posts) of the first and second terminals 70, 72 atsubstantially the same level as a top cover 78 of the first lithium ionbattery module 28 of FIG. 4, a top cover 80 of the second embodiment ofthe lithium ion battery module 28B of FIG. 5 (which may be the same asthe top cover 78), and a top cover 82 of the third embodiment of thelithium ion battery module 28C of FIG. 6. In this regard, the terminalposts 74, 76 may not protrude beyond an outer surface of the lithium ionbattery modules 28, which may reduce the likelihood that the terminals74, 76 will be subjected to tangential forces, short circuits, and soforth, that could potentially damage the lithium ion battery modules 28.The terminal regions 58, 60 may, in some embodiments, be the same sizefor the different lithium ion battery modules 28, in terms of volume orany one of a length, width, height, or any combination thereof, towithin manufacturing tolerances. In certain embodiments, a top cover(e.g., top cover 78) may be configured to interchangeably cover the topportions of the lithium ion battery modules 28A and 28B of FIGS. 4 and5.

In the illustrated embodiments of FIGS. 4-6, immediately adjacent to thefirst terminal region 58 is the venting region 66 including a vent plug84, which is a common component for the different lithium ion batterymodules 28. The vent plug 84 may be configured to open a vent of thelithium ion battery module 28 after an internal portion of the housing40 reaches a pressure threshold (e.g., as a result of a battery cellrupture).

The first and second embodiments of the lithium ion battery modules 28in FIGS. 4 and 5, respectively, may include additional sharedcomponents. For example, the first and second embodiments of the lithiumion battery modules 28 of FIGS. 4 and 5, respectively, may include acommon fan assembly 86, which may include a filter portion 88 includinga fan filter, and a fan portion 90 including a fan. The common fanassembly 86 of the first and second embodiment of the lithium ionbattery modules 28 of FIGS. 4 and 5 may also include a cover that isspecifically configured (e.g., shaped and sized and having specificconnection features) to couple with the respective top portions 48 ofthe first and second lithium ion battery modules 28 of FIGS. 4 and 5.

It is now recognized that the ability to utilize interchangeable andmodular components across the different embodiments (i.e., types,versions) of the lithium ion battery modules 28 may result in theability to manufacture the lithium ion battery modules 28 according tomore efficient processes, such as performed by the embodiment of amanufacturing system 100 shown in FIG. 7. Such a process may be moreefficient than a traditional manufacturing process in that differenttypes of lithium ion battery modules may be formed using shared assemblyregions, shared component sources, and so forth, which may reducecapital costs and increase the speed of manufacturing. The sharedassembly regions and shared component sources may include commoncomponents of the same type, size, and overall configuration, to withinmanufacturing tolerances, that can be used in any one or a combinationof different types of the lithium ion battery modules (e.g., lithium ionbattery modules 28 having different output voltages, differentcapacities, and so forth).

As depicted, the manufacturing system 100 may include the use of aninitial set of shared source components 102, which may include, forexample, components that can be integrated into the respective housings40 of the different lithium ion battery modules 28. For example,overmolded components such as terminals, structural support components,and the like, shared by the different lithium ion battery modules 28 maybe incorporated into this particular portion of the system 100.

The initial shared source components 102 may be distributed amongdifferent areas of the manufacturing system 100 where the housings 40may be produced. For example, the initial shared source components 102(e.g., common heat sinks for in-molding with housings) may bedistributed to a first housing mold region 104 where the housing 40 ofthe first embodiment of the lithium ion battery module 28A may bemolded, to a second housing mold region 106 where the housing 40 of thesecond embodiment of the lithium ion battery module 28B may be molded,and/or to a third housing mold region 108 where the housing 40 of thethird embodiment of the lithium ion battery module 28C may be molded.From these regions, the different module housings 40 may be provided tovarious module component integration regions 110, where differentportions of the modules are provided to the housings 40 for modulecompletion.

The module component integration regions 110 may include, as shown, abattery cell (electrochemical cell) shared source 112, which providesthe same type of battery cell (e.g., prismatic lithium ionelectrochemical cells having the same manufacturing specifications) tothe different module housings 40 in their respective cell receptacleregions 50. Other shared source components 114 may be similarlyprovided, including fans, fan covers, fan filters, printed controlboards, bus bars, vent plugs, and the like. Non-shared source components116 provided at the regions 114 may include size-specific components,such as integrated bus bar and voltage sense carrier assemblies, certaintypes of relays, front covers, thermal gap pads, and the like. As aresult of the integration of these various components into the threedifferent housings 40, the first, second, and third embodiments of thelithium ion battery module 28, for example corresponding to the modules28A-28C, respectively, are produced.

An example embodiment of the component integration region 110 isdepicted in FIG. 8. As shown, the region 110 includes a first path 124that conveys intermediates for the first embodiment of the batterymodule 28A, a second path 126 that conveys intermediates for the secondembodiment of the battery module 28B, and a third path 128 that conveysintermediates for the third embodiment of the battery module 28C,wherein the term “intermediates” refers to incomplete versions of thebattery modules (e.g., the battery module housings 40 will some, but notall, of their respective components). As an example, the paths 124, 126,128 may correspond to one or more conveyance paths, such as conveyorbelts or the like, that traverse all or a portion of the region 110.

The illustrated embodiment includes a first version of the batterymodule housing 130 introduced along the first path 124, a second versionof the battery module housing 132 introduced along the second path 126,and a third version of the battery module housing 134 introduced alongthe third path 128. The first, second, and third versions of the batterymodule housing 130, 132, 134 may correspond, for example, to as-formedversions of the battery module housing 40 shown in FIGS. 4, 5, and 6,respectively. The as-formed versions may be provided, for example, aftermolding the housings in the first, second, and third housing moldingregions 104, 106, 108 of FIG. 7.

In the component integration region 110 of the system 100, the paths124, 126, 128 may converge in regions where a common component isintroduced to the different modules, while they diverge in regions wheresize-specific or other non-shared components are introduced to themodules 28. For example, as shown, the paths 124, 126, 128 convey thehousings 40 to a battery cell positioning region 136 that uses thebattery cell source 112. The battery cell positioning region 136, incertain embodiments, includes an automated system that positions batterycells in the housings 130, 132, 134 in a particular manner, for examplein a specific orientation and in a specific number for the differentembodiments of the battery module 28.

The paths 124, 126, 128 may then diverge from one another to separaterespective sections of a first component integration region, depicted asregion 138A for path 124, region 138B for path 126, and region 138C forpath 128. The regions 138A-138C utilize different sources of a componentnot shared by the different lithium ion battery modules 28, including afirst version of a first non-shared component 140A for region 138A, asecond version of the first non-shared component 140B for region 138B,and a third version of the first non-shared component 140C. As anexample, the different versions of the first non-shared component mayinclude size-specific components, such as structural supports (carriers)for integrated bus bar and voltage sense assemblies for each lithium ionbattery module 28, a front cover for each lithium ion battery module 28,and the like. It should be noted that conveyance of different partialbattery module assemblies on an area for shared components may beavoided in accordance with present embodiments by distributing theshared components from a common source (i.e., a source of a set of thesame type of component having the same dimensions and configuration, towithin manufacturing tolerances).

The illustrated component integration region 110 may also includeadditional regions where common (i.e., interchangeably couplable)components are provided to the different types of the lithium ionbattery module 28. Such embodiments are intended to be represented by asecond component integration region 146 that utilizes a second sharedcomponent 148 (and/or source thereof), where the different types of thelithium ion battery module 28 may be fitted with common components, suchas the same fan assemblies, the same bus bars, the same electricalconnectors, and so forth. It should be noted that such modularity of thedifferent versions of the lithium ion battery module 28 may be a resultof all the lithium ion battery modules 28 having a corresponding region(e.g., a recess having a particular shape) for these different commoncomponents, including connectors, receptacles, spaces, or the like, thatare specifically configured to receive the shared components. Further,the component integration region 110 may include more regions whereadditional components, from shared or non-shared sources of thesecomponents, may be used to integrate the components with the lithium ionbattery modules 28.

The modular aspect of the lithium ion battery modules 28 describedherein may be further appreciated with respect to FIGS. 9 and 10, whichdepict exploded perspective views of the first, second, and thirdembodiments of the lithium ion battery module 28A, 28B, and 28C,respectively. Specifically, as shown in FIG. 9, a comparison between thefirst and second lithium ion battery modules 28A, 28B demonstrates thatthe two modules 28 have a similar architecture, and have a number ofshared components.

Starting from their respective housings 40A and 40B, it can be seen thatwhile the respective heights H1, H2 (FIGS. 4 and 5) of the two aredifferent, they actually have a very similar configuration. For example,the housing 40A of the first embodiment of the lithium ion batterymodule 28A and the housing 40B of the second embodiment of the lithiumion battery module 28B each have a layout including a plurality ofregions (e.g., the terminal regions, the relay regions, and so forth).Each region of the plurality of regions has a particular location on therespective housings 40A, 40B, and is configured to mechanically coupleto a particular component, such as control boards, relays, plugs, and soon. The particular locations and particular components of the pluralityof regions of the first and second embodiments of the lithium ionbattery modules 28A, 28B match (e.g., have the same correspondinglocation and the same type of component).

For instance, the illustrated lithium ion battery modules 28A, 28Binclude a common electrochemical cell 160, meaning that theelectrochemical cells 160 used in the different embodiments of thelithium ion battery modules 28 have the same manufacturingspecifications, including the same chemistry (e.g., cathode and anodeelectrode active materials, electrolyte, additives) and the same sizemanufacturing specifications, to within a specified tolerance. Inaccordance with an aspect of the present disclosure, it is nowrecognized that certain types of electrochemical cells may benefit suchapproaches more than others. For example, in one embodiment, theelectrochemical cells 160 may have a particular combination of anodeactive materials (e.g., including Li₄Ti₅O₁₂, which is lithium titanate(LTO)) and cathode active materials (e.g., includingLiNi_(1/3)Co_(1/3)Mn_(1/3)O₂, which is nickel cobalt manganese oxide(NMC)) that prevent them from swelling beyond a predetermined threshold.For example, in the illustrated embodiments, the electrochemical cells160 have a prismatic casing 162. The prismatic casings 162 are subjectto, and may conform to, a set of manufacturing specifications, includingtheir size in all dimensions.

The prismatic casings 162 include a top casing portion 164 where a setof cell terminals 166, 168 (e.g., positive and negative cell terminals)are located. One or more cell vents 170 may also be located on the topcasing portion 164. The set of cell terminals 166, 168 for each of theelectrochemical cells 160 enables the cells to be electrically connectedto various electrical components, including each other, to the terminals70, 72 of the lithium ion battery module 28, and a load to which thelithium ion battery module 28 may be coupled. The cell vents 170 areconfigured to enable venting of gases under certain conditions.

The prismatic cell casings 162 also include a bottom casing portion 172positioned opposite the top casing portion 164, first and second roundedsides 174, 176 that extend between the bottom and top casing portions172, 164 proximate the cell terminals 166, 168, and first and secondfaces 178, 180 that couple the first and second rounded sides 174, 176at opposing ends of each cell 160. The presently disclosedconfigurations may be, in some embodiments, facilitated by the presentlyillustrated orientation of the electrochemical cells 160 within thehousings 40. Specifically, the electrochemical cells 160, which areprismatic in FIGS. 9 and 10, are situated in the housings 40 with theirrespective sets of terminals 166, 168 pointed outward from the cellreceptacle regions 50. Further, the electrochemical cells 160 rest onone of their two faces 178, 180 within the lithium ion battery modules28, and the electrochemical cells are in a stacked arrangement in whichthe faces 178, 180 are oriented substantially parallel with respect toone another in a particular column 182 having a plurality (i.e., morethan one) electrochemical cells 160. In the embodiments illustrated inFIGS. 9 and 10, the electrochemical cells 160 are arranged in two suchcolumns 182, with the number of rows depending on the number of totalelectrochemical cells 160.

Such an arrangement may be desirable, for example, to maintain standarddimensions for the base 42 across the different embodiments of thelithium ion battery modules 28. Indeed, it is now recognized that acombination of the cell chemistry (e.g., NMC/LTO electrochemical cells),cell shape (e.g., prismatic), and cell size may provide advantages thathave not traditionally been used to achieve the technical effects setforth herein. For example, it is now recognized that NMC/LTOelectrochemical cells may enable a total cell volume to be defined forthe housing, and the remaining layout of the battery modules 28 to bedefined relative to this volume.

As noted above, the terminals 70, 72 of the lithium ion battery modules28 are all the same across the different embodiments described abovewith respect to FIGS. 4-6. In addition, their illustrated ventconfigurations are also the same—where the battery modules 28 may usethe same type of closure, securement, and venting features, such as acommon set of threads and screws, a common side plug 190, and a commonvent opening 192 into which a common barbed fitting 194 of acorresponding size may be used to enable the vent opening 192 to becoupled to a vent hose of the xEV 10 (where the xEV is shown in FIG. 2).As an example, the first and second embodiments of the lithium ionbattery module 28A, 28B, may each include a respective set of commoncomponents, and the common components may represent between 60% and 95%of a total part count of the first and second embodiments of the lithiumion battery modules 28A, 28B. For example, the common components mayrepresent between 60% and 90% of the total part count, between 65% and85% of the total part count, or between 70% and 80% of the total partcount of the lithium ion battery modules 28A, 28B.

Further, it should be noted that the respective layouts of the differentlithium ion battery modules 28 described herein are substantially thesame. For example, the relative location of the components of thedifferent embodiments of the lithium ion battery modules 28 is the same(i.e., matching) for each module 28. This includes, for example, theregions described above with respect to FIG. 3.

With respect to their electrical components, the first and secondembodiments of the lithium ion battery modules 28 include a common relay200 configured to electrically couple and de-couple one of the terminals(e.g., the first terminal 70) to an electrical load, and a common set ofelectronics 202. The electronics 202 may include the same shape and sizeof circuit board, as well as the same electrical architecture (e.g.,components, location, and connections) and layout. For instance, asingle source of the electronics 202 is intended to be appropriatelyused in either the first embodiment or the second embodiment of thelithium ion battery module 28. The electronics 202 may include a controlboard, as shown, as well as various short circuit protection circuitry,a battery control module including control circuitry configured tocontrol operational parameters of the battery modules 28, and so forth.

The modularity of the present approaches is reflected in the differentregions of the housings 40, as well. For instance, the top portions 48of the housings 40 also include the control board region 62 and therelay region 64, which are all the same layout and configuration for thefirst and second embodiments of the lithium ion battery module 28. Thatis, the control board region 62 for both the first and secondembodiments of the lithium ion battery module 28 includes the samearrangement of prongs, connectors, and so forth, that enable the topportion 48 to mechanically couple to and secure the set of electronics202. In addition, the relay region 64 for both the first and secondembodiments of the lithium ion battery module 28 includes the samearrangement of prongs, connectors, and so forth, that enable the topportion 48 to mechanically couple to and secure the relay 200 (i.e., thesame type and configuration of relay). It should be noted that suchcommon configurations may enhance manufacturing capability, even fordifferent housing molds. For example, the top portion 48 of thedifferent lithium ion battery modules 28 may be the same, meaning thatif the housing 40, or the portion of the housings illustrated, areformed from different pieces, the top portion 48 may be produced at acommon source. Further, in embodiments where the housings 40 areone-piece molded units, then the mold tools used to mold the housings 40may utilize the same types of equipment, for example the same portion ofthe mold tool used to form the top portion 48.

Other illustrated and common electrical components include shunt bridges204 and relay bus bars 206. Indeed, various other connectors andfeatures may also be common to two or more of the lithium ion batterymodules 28. For example, the first and second embodiments of the lithiumion battery modules 28 may include a common low voltage connector 208that may be used to electrically couple the relay 200 to certaincomponents, for example to couple the lithium ion battery module 28 tothe xEV 10, and/or to electrically couple a common fan 210 to thelithium ion battery module 28 to power the fan 210.

The top cover 78, over which the fan 210 is disposed, is also common forthe first and second embodiments of the lithium ion battery modules 28.Further, as noted above, the fan assembly 86 is also common between thetwo, including a fan filter 212. The manner in which a back cover 214 ofthe fan assembly 86 interfaces with the first and second embodiments ofthe lithium ion battery modules 28 may also be the same.

The third embodiment of the lithium ion battery module 28C, as shown inFIG. 10, also includes common components as set forth above. Indeed, inaddition to having the same general layout as set forth above for thefirst and second embodiments of the lithium ion battery module 28A, 28B,the third embodiment of the lithium ion battery module 28C also uses thesame shunt bridge 204, relay bus bar 206, terminals 70, 72, side plugs190, and barbed fittings 194, among others. As noted above, the modularaspect of the lithium ion battery modules 28 also includes the use ofthe common electrochemical cell 160.

Furthermore, while a respective relay 220 and a respective set ofelectronics 222 may be different for the third embodiment of the lithiumion battery module 28C compared to others, the relative layout andplacement of these features on its respective top portion 48 of thehousing 40 is substantially the same (i.e., matches the first and secondembodiments of the lithium ion battery modules 28A-28C). Furthermore,because these components are different, the electronics region 62 andthe relay region 64 of the third embodiment of the lithium ion batterymodule 28C may be different compared to the others illustrated. Forexample, its layout of connectors, prongs, and so forth, may bedifferent but generally located in a matching position as set forth formodules 28A and 28B.

One or more of the disclosed embodiments, alone or on combination, mayprovide one or more technical effects including the use of a number ofshared components across different battery modules having differentelectrical characteristics. For example, two or more battery modules,each having a different number of electrochemical cells, may include anumber of components that are provided by a common source. The use ofsuch common components facilitates manufacturing and reduces associatedcosts by enabling faster manufacture and greater compatibility betweenbattery modules. The technical effects and technical problems in thespecification are exemplary and are not limiting. It should be notedthat the embodiments described in the specification may have othertechnical effects and can solve other technical problems.

While only certain features and embodiments have been illustrated anddescribed, many modifications and changes may occur to those skilled inthe art (e.g., variations in sizes, dimensions, structures, shapes andproportions of the various elements, values of parameters (e.g.,temperatures, pressures, etc.), mounting arrangements, use of materials,colors, orientations, etc.) without materially departing from the novelteachings and advantages of the disclosed subject matter. The order orsequence of any process or method steps may be varied or re-sequencedaccording to alternative embodiments. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the invention.Furthermore, in an effort to provide a concise description of theexemplary embodiments, all features of an actual implementation may nothave been described. It should be appreciated that in the development ofany such actual implementation, as in any engineering or design project,numerous implementation specific decisions may be made. Such adevelopment effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure, without undue experimentation.

1. A lithium ion battery module product portfolio, comprising: a firstlithium ion battery module product comprising a first housing configuredto receive a first set of prismatic electrochemical cells, the housingincluding a base having a first footprint; a second lithium ion batterymodule product comprising a second housing configured to receive asecond set of prismatic electrochemical cells, the second housingincluding a base having a second footprint that is substantially thesame as the first footprint, wherein a vertical profile opposing thebase of the first and second housings is different for each of the firstand second lithium ion battery module products; each prismaticelectrochemical cell of the first and second sets of prismaticelectrochemical cells conforming to the same manufacturingspecifications, wherein the first housing of the first lithium ionbattery module product is sized to fit a first number of the prismaticelectrochemical cells, the second housing of the second lithium ionbattery module product is sized to fit a second number of the prismaticelectrochemical cells, and the first and second numbers of the prismaticlithium ion electrochemical cells are different; and a componentconfigured to interchangeably couple with a first region of the firsthousing of the first lithium ion battery module product and a secondregion of the second housing of the second lithium ion battery moduleproduct, the first and second regions having corresponding locations onthe first and second housings.
 2. The lithium ion battery module productportfolio of claim 1, wherein the first and second housings eachcomprise a pair of terminal regions and a pair of terminals located inthe pair of terminal regions, the respective pairs of terminal regionsof the first lithium ion battery module product and the second lithiumion battery module product have the same size and are located incorresponding locations on the respective first and second housings. 3.The lithium ion battery module product portfolio of claim 1, wherein thecomponent is a relay configured to interchangeably couple with both ofthe first and second lithium ion battery module products, wherein thefirst region comprises a first relay region and the second regioncomprises a second relay region, and the first and second relay regionseach comprises a set of connectors configured to mechanically couple tothe relay.
 4. The lithium ion battery module product portfolio of claim1, wherein the component is a control board having control circuitryconfigured to control operational parameters of the first and secondlithium ion battery module products, wherein the first region comprisesa first control board region and the second region comprises a secondcontrol board region, and the first and second control board regionseach comprises a set of connectors configured to mechanically couple tothe control board, and wherein the first and second control boardregions are positioned on corresponding top portions of the first andsecond housings, the corresponding top portions being located oppositethe respective bases of the first and second lithium ion battery moduleproducts.
 5. The lithium ion battery module product portfolio of claim1, wherein the component is a barbed fitting configured to interfacewith a vent hose of an xEV, wherein the first region comprises a firstvent region located on a side of the first housing of the first lithiumion battery module product and the second region comprises a second ventregion located on a side of the housing of the second lithium ionbattery module product, the first and second vent regions are configuredto mechanically couple to the barbed fitting, and are each positioned ona corresponding side portion of the respective housing, thecorresponding side portion being located between the respective base anda respective top portion opposite the respective base.
 6. The lithiumion battery module product portfolio of claim 1, wherein the componentis a fan assembly having a fan, a fan cover, a fan filter, and a fanfilter cover, wherein the first and second housings of the first andsecond lithium ion battery module products each comprise a top portionconfigured to mechanically couple to the fan assembly, and the fan coveris shaped to conform around a section of the respective top portions. 7.The lithium ion battery module product portfolio of claim 1, wherein thefirst and second housings comprise respective top portions opposite thebases, the top portions having electrical layouts comprising regionsconfigured to mechanically couple with a control board and a relay, andthe component comprises a top cover configured to interchangeably coverthe top portion of the first and second lithium ion battery moduleproducts.
 8. The lithium ion battery module product portfolio of claim1, wherein the first housing and the second housing each have a layoutcomprising a plurality of regions, each region of the plurality ofregions having a particular location on the respective housing and beingconfigured to mechanically couple to a particular component, and theparticular locations and particular components of the plurality ofregions of the first and second lithium ion battery module products arematching.
 9. The lithium ion battery module product portfolio of claim8, wherein the first and second lithium ion battery module products eachcomprise a respective set of the particular components, the particularcomponents representing between 60% and 95% of a total part count of thefirst and second lithium ion battery module products.
 10. The lithiumion battery module product portfolio of claim 9, wherein the particularcomponents of each of the first and second lithium ion battery moduleproducts comprise a relay configured to couple a voltage output of therespective number of prismatic electrochemical cells with a terminal ofthe respective battery module product, a top cover for a correspondingtop portion of the first and second housings positioned opposite theirrespective bases, a control board comprising circuitry configured tocontrol operational parameters of the first and second lithium ionbattery module products, a low voltage connector configured to couplethe relay with an xEV, and terminals configured to provide a voltageoutput of the first and second lithium ion battery module products. 11.The lithium ion battery module product portfolio of claim 10, whereinthe first housing comprises a first cell receptacle region, and whereinthe second housing comprises a second cell receptacle region that islarger than the first cell receptacle region, and the first and secondcell receptacle regions are configured to hold the first and secondnumbers of prismatic electrochemical cells in the first and secondlithium ion battery module products, respectively.
 12. The lithium ionbattery module product portfolio of claim 11, wherein the first numberof the prismatic electrochemical cells of the first lithium ion batterymodule product are electrically coupled as a group such that the firstlithium ion battery module product has a first voltage output and afirst capacity, and wherein the second number of the prismaticelectrochemical cells of the second lithium ion battery module productare electrically coupled as a group such that the second lithium ionbattery module product has a second voltage output and a secondcapacity, wherein the second voltage output is the same as the firstvoltage output, and the second capacity is larger than the firstcapacity.
 13. The lithium ion battery module product portfolio of claim12, wherein the first and second voltage outputs are 12 volts (V), thefirst capacity is 10 amp-hours (Ah), and the second capacity is 20 Ah.14. The lithium ion battery module product portfolio of claim 1,comprising a third lithium ion battery module product comprising a thirdhousing configured to receive a third set of prismatic electrochemicalcells, the third housing having a respective base with a third footprintas the first and second lithium ion battery module products, and arespective vertical profile of the third housing is different than therespective vertical profiles of the first and second lithium ion batterymodule products; wherein the third housing is sized to fit a thirdnumber of the prismatic electrochemical cells, and the third number ofthe prismatic electrochemical cells is greater than the first and secondnumbers; and wherein the third housing comprises a third region, and thecomponent is configured to interchangeably couple with the first,second, and third regions.
 15. The lithium ion battery module productportfolio of claim 1, wherein the prismatic electrochemical cells eachhave a cathode including lithium nickel cobalt manganese oxide (NMC)(e.g., LiNi_(1/3)Co_(1/3)Mn_(1/3)O₂) as a cathode active material, andan anode including LTO (Li₄Ti₅O₁₂) as an anode active material.
 16. Amethod of manufacturing lithium ion battery modules, comprising:producing a first lithium ion battery module by a first processcomprising: disposing a first number of prismatic electrochemical cellshaving a set of standardized dimensions in a first housing, the firsthousing having a first base with a length and a width; and electricallyconnecting the first number of prismatic electrochemical cells such thatthe first lithium ion battery module has a first voltage and a firstcapacity; producing a second battery module by a second processcomprising: disposing a second number of prismatic electrochemical cellshaving the set of standardized dimensions in a second housing differentfrom the first housing, the second housing having a second base with thelength and the width; and electrically connecting the second number ofprismatic electrochemical cells such that the second lithium ion batterymodule has a second voltage and a second capacity; wherein the firstprocess and the second process collectively comprise using a type ofcomponent configured to interchangeably couple with a first region ofthe first housing of the first lithium ion battery module and a secondregion of the housing of the second lithium ion battery module, thefirst and second regions having the same location on their first andsecond housings, respectively.
 17. The method of manufacturing lithiumion battery modules of claim 16, wherein electrically connecting thefirst number of prismatic electrochemical cells such that the firstlithium ion battery module has the first voltage and the first capacitycomprises connecting the first number of prismatic electrochemical cellsserially to provide a 12 volt (V) output, and a 10 amp-hour (Ah)capacity, and wherein electrically connecting the second number ofprismatic electrochemical cells such that the second lithium ion batterymodule has the second voltage and the second capacity comprisesconnecting the second number of prismatic electrochemical cells in acombination of serial and parallel connections to provide a 12 V output,and a 20 Ah capacity.
 18. The method of manufacturing lithium ionbattery modules of claim 16, comprising: producing a third lithiumbattery module by a third process comprising: disposing a third numberof prismatic electrochemical cells having the standardized dimensions ina third housing different from the first and second housings, the thirdhousing having a third base with the length and the width; andelectrically connecting the third number of prismatic electrochemicalcells such that the third lithium ion battery module has a third voltageand a third capacity; and wherein the first, second, and third number ofprismatic electrochemical cells are different, and the first base, thesecond base, and the third base all have the same length and width. 19.The method of manufacturing lithium ion battery modules of claim 18,comprising performing the first and second processes using a pluralityof components that are each configured to interchangeably couple withthe first and second lithium ion battery modules and third lithium ionbattery modules, but not the third lithium ion battery module.
 20. Themethod of manufacturing lithium ion battery modules of claim 19, whereinthe components comprise a relay configured to couple a voltage output ofthe respective number of prismatic electrochemical cells with a terminalof the respective battery module, a top cover for a top portion of therespective housings positioned opposite the respective bases, a controlboard comprising circuitry configured to control operational parametersof the first and second lithium ion battery modules, a low voltageconnector configured to couple the relay with an xEV, and terminalsconfigured to provide a voltage output of the first and second lithiumion battery modules.
 21. The method of manufacturing lithium ion batterymodules of claim 19, comprising performing the first, second, and thirdprocesses using a plurality of components that are each configured tointerchangeably couple with the first, second, and third lithium ionbattery modules.
 22. The method of manufacturing lithium ion batterymodules of claim 18, wherein the prismatic electrochemical cells eachhave a cathode including lithium nickel cobalt manganese oxide (NMC)(e.g., LiNi_(1/3)Co_(1/3)Mn_(1/3)O₂) as a cathode active material, andan anode including LTO (Li₄Ti₅O₁₂) as an anode active material.
 23. Themethod of manufacturing lithium ion battery modules of claim 16, whereinthe first and second processes collectively comprise: conveying thefirst and second housings along a first path and a second path,respectively, in a manufacturing system; converging the first and secondpaths in a first module integration region of the manufacturing systemwhere a source of the component configured to interchangeably couplewith the first and second lithium ion battery modules is located;integrating a first one of the component with the first housing and asecond one of the component with the second housing; converging thefirst and second paths in an additional module integration region of themanufacturing system where a source of an additional componentconfigured to interchangeably couple with the first and second lithiumion battery modules is located; and integrating a first one of theadditional component with the first housing and a second one of theadditional component with the second housing.
 24. A lithium ion batterymodule product portfolio, comprising: a first lithium ion battery moduleproduct having a first layout, comprising: a first module housingconfigured to house a first set of electrochemical cells, wherein thefirst module housing comprises: a first top portion having terminalsconfigured to provide a voltage output of the first lithium ion batterymodule product; a first base disposed opposite the top portion andhaving a set of dimensions; and a first cell receptacle region disposedbetween the first top portion and the first base, the first cellreceptacle region being configured to receive the first set ofelectrochemical cells in an orientation; and a second lithium ionbattery module product having a second layout, comprising: a secondmodule housing configured to house a second set of electrochemicalcells, the second set of electrochemical cells having a greater numberof electrochemical cells compared to the first set of electrochemicalcells, wherein the second module housing comprises: a second top portionhaving terminals configured to provide a voltage output of the secondlithium ion battery module product; a second base disposed opposite thesecond top portion and having the same set of dimensions as the firstbase; and a second cell receptacle region disposed between the secondtop portion and the second base, the second cell receptacle region beingconfigured to receive the second set of electrochemical cells in theorientation; and a plurality of components configured to interchangeablycouple with a plurality of corresponding first regions of the firstbattery module housing and a plurality of corresponding second regionsof the second module housing, and the first and second layouts are suchthat the corresponding first and second regions have the same locationon their respective housings.